Method and apparatus for creating a kneeler pad using a thermoforming process

Abstract

The present invention is a system and method for manufacturing a framework for a padded cushion in the shape of a kneeler pad, wherein the framework is created using a thermoforming process to make rigid and plastic top and bottom shells that are then coupled together to form a framework to which upholstery is added to thereby form a padded kneeling cushion, wherein a fabric tightening system is also installed in the framework that enables the upholstery to be stretched tighter over the framework in order to tighten the upholstery around the cushion as the upholstery loses its shape and stretches over time, and wherein a system is provided to extend a length of the kneeler pads through the addition of expansion segments in the framework.

What is claimed is: 
     
       1. A padded cushion having a fabric tightening system, said padded cushion comprised of:
 a framework for the cushion, wherein the framework includes a cavity in a top surface thereof, wherein the cavity has a bottom surface; 
 a lifting device disposed on the bottom surface of the cavity, wherein the lifting device may be actuated through a bottom surface of the framework; 
 a bottom plate disposed within the cavity and on top of the lifting device, wherein the bottom plate is not attached to but is floating within the cavity and on the lifting device, and wherein the bottom plate is rigid; 
 at least one interior foam pad disposed on top of the bottom plate and in the cavity of the framework; 
 at least one top foam pad disposed on top of the at least one interior foam pad and on a top edge of the framework; and 
 upholstery fabric disposed on top of the at least one top foam pad, around an exterior of the framework, and coupled to the bottom surface of the framework. 
 
     
     
       2. The padded cushion and fabric tightening system as defined in  claim 1  wherein the padded cushion is further comprised of a plurality of framework holes through the bottom surface of the framework so as to provide access to the lifting device. 
     
     
       3. The padded cushion and fabric tightening system as defined in  claim 2  wherein the padded cushion is further comprised of a base disposed on the bottom surface of the framework, wherein the base includes a plurality of base holes, wherein the plurality of base holes are aligned with the plurality of framework holes. 
     
     
       4. The padded cushion and fabric tightening system as defined in  claim 3  wherein the framework is further comprised of a top shell and a bottom shell, wherein the top shell includes the top surface and the cavity disposed therein. 
     
     
       5. The padded cushion and fabric tightening system as defined in  claim 4  wherein the bottom surface of the cavity is further comprised of a plurality of indentations that are substantially evenly spaced along the bottom thereof, and wherein each of the plurality of framework holes are disposed in a center of each of the plurality of indentations. 
     
     
       6. The padded cushion and fabric tightening system as defined in  claim 5  wherein the bottom surface is further comprised of a honeycomb structure to increase structural integrity of the framework, wherein a center of each honeycomb of the honeycomb structure corresponds to each of the plurality of indentations. 
     
     
       7. The padded cushion and fabric tightening system as defined in  claim 6  wherein the bottom shell is further comprised of a top surface that is a physical inverse of the bottom surface of the cavity in the top shell. 
     
     
       8. The padded cushion and fabric tightening system as defined in  claim 7  wherein the lifting device is further comprised of:
 a block disposed in each of the plurality of indentations on the bottom surface of the cavity; 
 a block hole disposed through a center of each of the blocks, wherein each of the block holes has an axis that is aligned with the plurality of framework holes; 
 a T-nut disposed in each of the plurality of framework holes; and 
 a bolt disposed in each of the T-nuts in the blocks, wherein a top surface of each bolt is in contact with a bottom surface of the bottom plate.